Multi-Piece Stator For An Electric Motor

摘要

A multi-piece stator includes a pole cluster, a flux ring, and an insulation member. A rotor cavity is located at a center of the pole cluster, and multiple flux poles extend radially outward from the rotor cavity in a circumferential arrangement. The pole cluster includes a flux impedance feature between each of the multiple flux poles, and multiple bridge features maintaining the arrangement of the flux poles. The flux ring includes a ring wall having a minimum wall thickness and a pole cluster cavity defined by the ring wall. The insulation member has a shape corresponding substantially to a shape of the pole cluster and is located to effectively cover an outside surface of the flux poles. The pole cluster, the insulation member, and a field generation coil wrapped around a portion of the insulation member and a portion of the pole cluster are inserted into the pole cluster cavity.

主权项

1. A stator for use in an electric motor comprising:
a pole cluster having a pole cluster axial thickness, a first cluster side, and a second cluster side substantially parallel to said first cluster side and offset from said first cluster side by a distance corresponding to said pole cluster axial thickness, said pole cluster comprising:
multiple layers of magnetic material;a rotor cavity located at a center of said pole cluster;multiple flux poles extending radially outward from said rotor cavity in a circumferential arrangement, each of said flux poles comprising:
a pole foot located proximate said rotor cavity;a pole body extending radially outward from said pole foot to a distal end; anda pole interface structure located on said distal end of said pole body;a flux impedance feature between said pole feet of each of said multiple flux poles;multiple bridge features, each comprising magnetic material extending from one of said pole feet of one of said multiple layers of said pole cluster to an adjacent pole foot corresponding to the same one of said multiple layers of said pole cluster; a flux ring having a flux ring axial thickness, a first ring side, and a second ring side substantially parallel to said first ring side and offset from said first ring side by a distance corresponding to said flux ring axial thickness, said flux ring comprising:
multiple layers of magnetic material;a ring wall having a minimum wall thickness;at least one ring interface structure on an inside wall corresponding to at least one pole interface structure;a pole cluster cavity defined by said ring wall;and wherein said multiple bridge features maintain said circumferential arrangement of said multiple flux poles relative to each other prior to an insertion of said pole cluster into said pole cluster cavity of said flux ring.